Process for making alternating twist slub yarn using a fluid vortex



11113710, 1952 A. L. BREEN ET 3,043,087

PROCESS FOR MAKING ALTERNATI TWIST SLUB YARN ING A FLUID VORTEX OriginFiled Dec. 22, 1959 e W 5 4 I/IIIjII/IIII and!!! III S j WW grwvwtmsALVIN LEONARD BREEN MARTIN VICTOR SUSSMA N United States Patent PROCESSFOR MAKING ALTERNATING TWIST SLUB YARN USING A FLUID VORTEX AlvinLeonard Breen, West Chester, Pa., and Martin Victor Sussman, Istanbul,Turkey, assignors to E. I. du Pont de Nemours and Company, Wilmington,Del., a corporation of Delaware Original application Dec. 22, 1959, Ser.No. 861,368, new Patentl lo. 2,997,837, dated Aug. 29, 1961. Divided andthis application Jan. 12, 1961, Ser. No. 83,606

4 Claims. (Cl. 57-157) This invention relates to a novel yarn productand process for preparing it, and more particularly to the process ofpreparing the slub yarns of application Serial No. 861,368, filedDecember 22, 1959, and is a division of that application. Saidapplication is now US. Patent No. 2,997,837 issued August 29, 1961.

According to this invention there is provided a slub yarn in which eachslub contains both 8 and Z twist. Such a yarn is prepared by passing acontinuous running filamentary carrier strand axially through a fluidvortex formed by a jet of fluid with velocity at least /2 sonic, therebytwisting the strand and causing it to balloon immediately upstream ofthe fluid vortex, feeding a second filamentary material to wrap aboutthe ballooning portion of the continuously running strand to form a sluband permitting the slub to be carried by the carrier strand through thefluid vortex where it'is wrapped firmly about the carrier strand withboth 8 and Z twist.

Typical slub yarns produced in accordance with this invention areshownin FIGURES I, II, and III of the attached drawing. FIGURE IVillustrates schematically a preferred embodiment of the process of thisinvention.

FIGURES V and VI illustrate one embodiment of a fluid but plied sectionsof the yarn are twisted in the twist direction that exists downstream ofthe twister.

FIGURE III shows a slub yarn which is referred to as a crepe tail slubyarn. It is made by processing at low tension of about 3 grams or less.The high twist imparted to the yarn by an elficient fluid twister atthis low ten- .sion causes the yarn to form branched slubs which passthrough the twister. The stability of the branched slubs can beincreased by size applied to the yarn before it en tcrs the twister.

FIGURE IV illustrates an assembly and process for producing the slubyarns of this invention. In using the assembly of FIGURE V, a continuousor staple filament yarn is unwound from 'package 140, passed over pin141, through nip rollers 142, and subjected to the crank twisting actionby fluid twister 143. The cranking action upon the yarn is shown bydotted lines 150. In

the specific illustration shown, short lengths of a second filamentarymaterial 144 are dropped from reservoir 145 upon the carrier yarn as itis cranked and twisted with the result that the short lengths offilamentary material are wound tightly about the cranking (carrier) yamand become firmly bound thereto to form slubs. Alternatively, the slubsmay be formed on the carrier yarn downstream of the fluid twister butthis procedure is less desirable because slubs are even more firmlybound to the carrying yarn as the yarn carrying the slubs passes throughfluid twister 143. The slub yarn product is then passed through niprollers 147 and wound on package roll 148 which is driven by drive roll149. In operating in accordance with this embodiment, the carrying yarnmay be either staple or continuous filament yarn, and the secondaryyarn, which is added to form slubs, may be short lengths of fibers oryarns or a staple or continuous filament yarn.

FIGURES V and VI show plane and end views, respectively, of arepresentative fluid twister useful in this in-. vention. In thistwister, axial yarn passageway 51 is substantially cylindrical in formthroughout its length. A conduit for fluid 52 intercepts the yarnpassageway at 53 at an angle of about degrees to the axis thereof and ispositioned so that the longitudinal axis of the fluid conduit 52 doesnot intersect the longitudinal axis of yarn passageway 51, as shown inFIGURE VI. When gas under pressure is passed through fluid conduit 52 sothat it reaches at least sonic velocity upon emerging into the yarnpassageway 51, suflicient torque upon any yarn in the yarn passageway iscreated to produce a high rate of crank twisting if the yarn ismaintained at a tension of less than about 15 grams. At relatively highfluid velocities less dense fluids may be employed to obtainsubstantially the same torque produced by a higher density fluidtraveling at lower velocity. Fluid may be supplied to the fluid conduit52 by any convenient means.

It is an important feature of this invention that during the twisting ofthe yarn bundle the yarn undergoes a cranking action, that is, thelongitudinal axis of the yarn describes a surface similar to the innersurface of the yarn passageway and spaced from the inner surface of theyam passageway by a distance equal to about the radius of the yarnbundle. This feature of the instant invention is illustrated in FIGUREVI. FIGURE VI illustrates direct twisting of a yarn bundle 59 in yarnpassageway 51 and shows, by arrows, that the yarn twists about its axisin the same direction as fluid flow about the inner periphery of theyarn passageway while the axis of the yarn bundle describes a surfacespaced from the inner surface of the yarn passageway by a distance atleast the radius of the yarn bundle, both surfaces having a commonlongitudinal axis.

Because the fluid twisting devices utilized in this invention twistyarns at exceedingly high rates (turns per minute) at exceedingly highthroughput speeds (yarns per minute), slub yarns of this invention maybe produced very efiiciently.

The fluid utilized in the fluid twisting device may be any compressiblefluid, but inert gaseous materials such as steam, air, nitrogen, carbondioxide, etc., are preferred. A wide variety of fluid twisters useful inthis invention and conditions for operating them are set forth inapplication Serial No. 598,135 filed July 16, 1956, by Breen andSussman. The manner in which the process conditions disclosed in thatapplication may be employed to produce a variety of slub yarns of thisinvention will be apparcut to one skilled the art, For purposes of thisinvention it is obviously necessary. to use a fluid twister having ayarn passageway sufiiciently large to permit smooth passage of bothcarrier yarn and slubs without undue friclayers of the slubbing yarn arewrapped. The tension on the carrier yarn is maintained constant atbetween 10 and 25 grams, whereas the tension on the slubbing yarn isvaried in a rapid and random fashion between and 25 Process twist";

tion or drag. The process of this invention isrparticularly grams.Wrap-ping occurs when the tension in the slubadvantageous not onlybecause of its efliciency and high bing yarn drops below the tension inthe carrier yarn. production rate, but also because the fluid vortexopens Layered slubs occur when the tension in the slubbin-g yarn up thecarrier yarn bundle sufliciently to insert and 'inter approaches zerograms. The wrapping and carrying funcmingle slub yarn fibers between andamong fibers of the tions of eachyarn may be reversed by reversing therelacarrier yarn, thereby producing a slubiyarn in which the tivetension levels. Process conditions are shown in Exslubs, in addition totheir unique twist, are firmly attached ample II of Table I. 1 to thecarrier yarn, A fluid twister is particularly adapted to making of Inoperating-the process of this invention, yarn tension 5111b Ya Since thetwister Y Passage ofiefs little is generally maintained at less thanabout half the breaksistance to the passag of a wheffifis mechanical ingtension of the yarn being processed and preferably betwisters snub theyarn over pins, wheels, etc., which would tween about 0.1 and about 25grams, Twisting rates ofier substantial resistance to the passage ofslubs, with equivalent to between 100,000 and 1,200,0(l0 turns per theresult that the threadline would be subject to firequent minute areeasily obtained. breakdowns. V

The following examples illustrate the invention. By varying the tensionof the carrier yarn as vpasses EXAMPLE I throughthe fluid twister, inaccordance with the disclosure a V V in copending application Serial No.598,135 filediluly 16, I Using the setup shown in FIGURE IV,poly(hexameth- 1956, by Breen and Suss'ma'n, the carrier yarn'is formedylene adipamide) yarn is taken from apackage, passed into an alternatingtwist configuration and'the slubs are through the feed rolls, through afluid twister operating on wrapped about this yarn so that the productis a slub yarn 40 pounds per square inch air to a windup roll, andfinally in which the carrier portion of the filaments possesses a to abaclcwindable package; Windup speed is 160 y.p.m. variable degree oftwist or possibly alternating twist. In Tension in the threadline ismaintained at 10 grams. 7 the yarn of FIGURE II, for example, thecarrier filament Immediately upstream of the twister, pieces of staplebundle between slubs has a twist opposite to that of the yarn (1.5denier per filament, 3 inch viscose) are fed to slubs whereas thecarrier filament bundle within the slubs the cranking, twistingthreadline from a hopper. On conhas a twist in the same direction as theslubs.

Table I Example I Example II Carrier Slub Carrier Slub Yarn materialp0ly(hexamethyl- Viscose" poly(hexamethyl- Viscose.

' one adipamide) ene adipamide).

Initial Twist--. Feed speed (y.p.m.) Windup speed (y.p.m.).-. 160Tension (gms) 0-25.

yarn is shown in FIGURE 1. in that the slub is held to the carrier yarnwith two direc- Fluid twister."

Heat-setting t C Type heater T Twisting action Direct Direct Productcharacterization. Slub Yarn Air Passage diameter 7 (inches); 1 hole at.040

Yarn Passage diameter inches) .063"

tactung the cranking, twisting threadhne, the staple fibers EXAMPLE III,

are immediately entrained into the threadline by the rapid V crankingrotation, and form randomly spaced slubs along the threadlin e. ,Anenlarged illustration of the slubbed The slub yarn is novel tionsoft-twist. One end of the slub is twisted in the S di rection, the otherend is twisted in theZ direction. The process conditions are shown inExample'l of Table 1.

EXAMPLE 11' A slub yarn comprising slubs of continuous filament onacontinuous filament carrier yarn is prepared by substituting acontinuous filament package for the reservoir 145 The procedure ofExample I is followed except that sure, continuous filament yarn whichis to' be used for slubbing, is allowed to contact the rotating carrieryarn .threadline. The slubbingyarn is immediately wrapped about thecarrier yarn andforms slubs which consist of short sections of carrieryarn about which numerous the yarn to form branched slubswhich passthrough the twister. The product is a so-called -crepe tail slub yarn asillustrated in FIGURE, IH. The stability of the branched slubs can beimproved 'byapplication of size to the yarn before it enters thetwister. J

A similar slub yarnis produced by plucking a threadline passing throughthe twister so as to create short rapid tension changes; Of course, theover-all tension should be maintained low. a

' The examples in Table II illustrate the operation of g the processorthis invention under various conditions and with'a variety of yarns,both natural and synthetic.

.Air was used as the'twisting fluid in all examples, and

air velocity was at least /2 sonic. I V, W This application is acontinuation-in-part of application Serial No. 598,135 filed Iuly'16,1956, by Breen and .Sussman. 7 p v Table II Example IV Example V CarrierSlub Carrier Slub Yarn Material Dacron" Wool Silk "Orion". Denier- 25064's. 1 15 3. N0. Filaments 50 14 Source Spin Bobbin Cone Type of YarnContinuous Staple Continuous Staple. Initial Twist.-- 16 14 Z 0. FeedSpeed (y.p.m.) Tension Gate- Tension Gate- Intermittent. Windup Speed(y.p.m.).-.. 10 67 67. Tension (gms.) 0-20. Process Twist Z. FluidTwister.- Figs. V and VI. Air Pressure (p.s.1.g.)-..-.. 40. TwistingAction Direct. Product Characterization Slub Yarn. Ai(r hPassageDiameter 1 hole at .0625.. .0625 1 hole at .0625- .0625.

inc es Yarn Passage Diameter .1250 .1250 .1250 .1250.

(inches).

Example VI Example VII Carrier Slub Carrier Slub Yarn Material WoolNylon Orion Dacron." Denier. 18s cc 100 3. NO. Filaments 4O Source CoTube Type of Yarn. Spun Smnle Continuous Staple. Initial Twist 122-- 0.37 0. Feed Speed (y.p.m.)-- Tension Gate.. Intermittent Tension Gate.Intermittent. Windup Speed (y p m. 67 67 67. Tension (gms.) 5-20 0-20-20 0-25. Process Twist Z Z Z. Fluid Twister Figs. V and VI.-.. Figs. Vand VI Figs V and VI.-.. Figs. V and VI. Air Pressure (p.s.i.g.)- 40 4040.. 40. Twisting Action Direct Direct Direct Direct. ProductCharacterization Slub Yaru.. Slub Yarn Slub Yarn.; Slub Yarn. Ai(rhPa)ssage Diameter 1 hold at .0625 .0625 1 hold at .0625-.--- 25.

inc es Yarn Passage Diameter 1250 .1250 .1250 .1250.

(inches).

Example VIII Example IX Cartier Slub Carrier Slub Yarn Material Dacron"Acetate Nylon Orion. Denier- 7 300 70.-. 3. No. Filaments--- 34 80 34Source Spin Bobbin Cake Pirn.-- Type of Yarn ContinuousContinuous.----... Continuous Staple. Initial Twist 0 Z 0. Feed Speed(y.p.m.) Tension Gate.- Intermittent Tension Gate--.-- lnlgerllrinttent10 up. Windup Speed (y.p.m.).-.. 67 67-100 67.. 67. Tension (gins) 10-200-20 -25 Process Tw Z Z-- Z Z. Fluid Twister Figs. V and VI-. Figs. Vand VI.... Figs. V and VI..- Figs. V and VI. Air Pressure (p.s.i.g.)..-40 40 40. Twisting Action Direct Dire-0t Direct Direct. ProductCharacterization-. Slub Yarn Slub Yarn Slub Yarn Slub Yarn. Air PassageDiameter 1 hole at .0625..- 1 hole at .0625--- .0625.

(inches). Yarn Passage Diameter .1250.. .1250.- .1250 .1250.

(inches).

Example X Example XI Carrier Slub Carrier Slub Yarn Material Nylon(Bulk)- Cotton Middling.. Egyptian Cotton.. Middling Cotton. Denier---28's on No. Filaments.-.- 34

ource. Pirn. Cone Type of Yarn Continuous Staple Spun Staple. InitialTwist. 1/22 0 24-1-2.-. 0. Feed Speed (y.p.m.) Tension Gate..---Intermittent Tension Gate.--" Intermittent. Windup Speed (y.p.m.) 67 6767 67. Tension (gins) 10-20 0-25 15-20 0-20. Process Twist Z.-. Z Z-.-Z. Fluid Twister Figs. V and VI-- Figs. V and VI-... Figs. V and VL-.-Figs. Vand VI. Air Pressure (p.s.i.g.) 30 30 4o 40. Twisting ActionDirect Direct Direct Direct. Product Characterizatiom- Slub Yarn..- SlubYarn- Slub Yarn--. Slub Yarn. Air Passage Diameter 1 hole at .0625--.-.1 hole at .0625 .0625.

(inches). Yarn Passage Diameter (inches) 1250-- .1250-- .1250 .1250.

T able IIContinued l. A process comprising passing a continuous runningfilamentary carrier strand axially through a fluid vortex formed by ajet of fluid'with velocity at least /2 sonic, thereby twisting thestrand and causing it to balloon immediately upstream of the fluidvortex, feeding a second filamentary material to wrap .about theballooning portion of the continuously runningstrand to form a slub andpermitting the slub to be carried by the carrier strand through thefluid vortex Where it is'wrapped firmly about the carrier strand.

2. The process of claim 1 in which the second filamentary material is inthe form of individual staple fibers.

Example XII Example XIII Carrier Slub Carrier Slub Yarn Material Dacron"Ny1on Nylon Dacron." Denier 10 7 4.75. No. Filaments- 34 34 Source" GonePirn- Pir Type of Yarn Spun C0ntinuous Continuous Staple. Initial Twist.2.5-.- i Z 1 7 Feed Speed (y.p.m.) Tension Gate. 67-100 TensionIntermittent; Windup Speed (y.p.m.). 61- 4n 40. Tension (gms) 5-10 o-m10-20 0-20, Process Tw Z e Z. Z Z. Fluid Twister Figs. V and VI Figs. Vand VI Figs. V and VI-- Figs. V and. VI. Air Pressure (p.s.i.g.) 4 40 4040. Twisting minu Dire Dir Direct Direct. Product Characterization SlubYarn Slub Yarn Slub Yarn Slub Yarn. Ai(r h]?a)ssage Diameter 1 hole at.0625.- .0625. 1 hole at .0625 .0625.

me as Yarn Passage Diameter .1250 .1250 .1250 .1250. (inches).

We claim: 3. The process of claim 1 in which thesecond filamentarymaterial is in the form of staple yarn.

4. The process of claim 1 in which the second filamen- 25 tary materialis a yarn of continuous filaments.

Refere'nces Cited in the file of this patent UNITED STATES PATENTS72,751,747 Burle'son June 26, 1956 p FOREIGN PATENTS 355,447 GreatBritain Aug. 27; 1931

